SYL-2362A2 PID TEMPERATURE CONTROLLER

Transcription

1 SYL-2362A2 PID TEMPEATUE CONTOLLE INSTUCTION MANUAL Version 2.4 Caution This controller is intended to control equipment under normal operating conditions. If failure or malfunction of it could lead to an abnormal operating condition that could cause personal injury or damage to the equipment or other property, other devices (limit or safety controls) or systems (alarm or supervisory) intended to warn of or protect against failure or malfunction of the controller must be incorporated into and maintained as part of the control system. Installing the rubber gasket supplied will protect the controller front panel from dust and water splash (IP54 rating). Additional protection is needed for higher IP rating. This controller carries a 90-day warranty. This warranty is limited to the controller only. 1. Features The PID control with artificial intelligent enhancement for precision temperature control. Auto-tuning function can find the best PID parameter automatically. On/off control mode for refrigerator, motor and solenoid valve control application. Bumpless transfer between Auto and Manual control. Limit control for safety protection and special applications. The output can be set for SS output control or relay contactor control by the user. Two contact relays can be configured as one PID and one alarm output, dual alarm outputs, or dual On/off control. Support 10 different types of commonly used temperature sensor inputs. 2. Specification Input type Thermocouple (TC): K, E, S,, J, T, B, We3/25 TD(esistance temperature detector): Pt100, Cu50 Input range See table 2 Display Dual lines, four digits, F or C Display resolution 1 C, 1 F; or 0.1 C, 0.1 F with Pt100 Accuracy ±0.2% or ±1 unit of full input range Control mode PID, On-off. Limit, Manual Output mode elay contact: 3A at 240VAC, SS: 8VDC, 40 ma. Alarm Process high/low alarm Power consumption <2 Watt Power supply 85~260VAC/50~60Hz or VDC Sample rate 4 samples/sec Operating condition 0 ~ 50 C, 85% H Mounting cutout 45 x 45 mm Dimension 48x48x75mm (1/16 DIN) 3. Front Panel and Operation Figure 1. Front panel 1 AL-1 elay J1 output indicator AL-2 elay output indicator AT/M- On for manual mode. Blinking during auto-tuning process OUT- SS output indicator 2 Value increment/select next parameter 3 Value decrement/select previous parameter 4 Auto tuning/digit shift 5 Set/Confirm/Manual Auto switching/eset (for Limit control mode) 6 Measured temperature, or, Process Value () 7 Set temperature, or, Set Value () 4. Terminal Wiring (back view) SS Power AC/DC V W NC TD J1 TC Figure 2. Wiring diagram 4.1 Sensor connection Thermocouple The thermocouple should be connected to terminals 9 and 10. Make sure that polarity is correct. There are two commonly used color codes for the K type thermocouple. US color code uses yellow (positive) and red (negative). Imported DIN color code uses red (positive) and green/blue (negative). The temperature reading will decrease as temperature increases if the connection is reversed. NO to terminal NC NO P1/5

2 4.1.2 TD sensor For a three-wire TD with standard DIN color code, the two red wires should be connected to the terminals 9 and 10. The white wire should be connected to terminal 8. For a two-wire TD, the wires should be connected to terminals 8 and 9. Jump a wire between terminals 9 and 10. Set controller input type, Inty, to P100 (1 resolution) or P10.0 (0.1 resolution). 4.2 Power to the controller The power cables should be connected to terminals 1 and 2. Polarity does not matter. It can be powered by V AC or DC power source. Neither a transformer nor jumper is needed to wire it up. For the sake of consistency with the wiring example described later, we suggest you connect the hot wire to terminal 2 and neutral to 1. Since the controller is in a plastic shell, ground wire is unnecessary. 4.3 Output connection Two control output options are offered by this controller. (1) The SS control output provides an 8V DC signal that can control up to 4 SSs in parallel. (2) The relay output can be used to turn on a contactor or a solenoid valve. It can also drive a small heater directly if the heater draws <3 Ampere. For application that needs two control outputs, such as one for heating and other for cooling, J1 relay can be used for the second output with on/off control mode. Please note J1 can t be used for main control output. Both J1 and can be used as alarm output if they are not used as control output Connecting the load through SS Connect terminal 7 to the negative input and terminal 6 to the positive input of the SS. Set the system output configuration, outy, to 2, 3 or 6 - depending on the control mode used. See Figure 10 for details Connecting the load through a contactor J1 relay is for alarm output only. Assuming the controller is powered by a 0V AC source and the contactor has a 0VAC coil, jump a wire between terminal 2 and. Connect terminal to one lead of the coil and terminal 1 to the other lead of the coil. Set the system output configuration, outy, to 1, 4, or 5 - depending on the control mode used. Please see Figure, and for examples. Note: For first time users without prior experience with PID controllers, the following notes may prevent you from making common mistakes: Power to the heater does not flow through terminal 1 and 2 of the controller. The controller consumes less than 2 watts of power. It only provides a control signal to the relay. Therefore, 20 gauge wires are sufficient for providing power to terminal 1 and 2. Thicker wires may be more difficult to install The J1, relay are dry single pole switches. They do not provide power by itself. Figure shows how it is wired when providing a 0V output (or when output has the same voltage as the power for controller). If the load of relay requires a different voltage than that for the controller, an additional power source will be needed (Please see the alarm wiring of Figure 10 and controller output of Figure for examples) SS output power does not come from the input of the SS. The output of the SS is a single pole switch between terminal 1 and 2 of the SS. The input of the SS is for control, or triggering, the SS. (Please note we are talking about the SS itself, not the SS control output of the controller). Figure 10 shows how the SS output should be wired. When switching a North American 240VAC power, the heater will be live even when the SS is off. Users should install a double pole mechanical switch to the power input. 5.1 System Configuration Parameters (accessed by code 0089) The system configuration parameters are listed in table 1. To change the parameters, press, enter code 0089 and press again. Then, follow the flow chart in Figure 3. Operation Mode Enter Code 0089 Figure 3. System setup flow chart (1) Press to enter setting mode; (2) Press >, and to enter parameters; (3) Press to confirm; (4) Press or to select the new parameter. Table 1. System configuration parameters Code Description Setting ange Initial Note Inty Inty Input Sensor Ty pe See table2 K 1 outy outy Control Output Mode 0, 1, 2, 3, 4, 5, Hy Hy Hy steresis Band 0~ Atdu Atdu Autotune Offset 0~200(deg) 10 4 PSb PSb Input Offset -100~100(deg) 0 5 rd rd Control Function 0: heating 1: Cooling 0 CorF CorF Display Unit 0: C 1: F 1 End End Ex it Note 1. The controller is preset for K type thermocouple input. If any other type of sensor is used, the Inty value needs to be changed to the corresponding symbol as shown in Table 2. Table 2. Temperature sensor code Sy mbol Description Parameter Display Working Temperature ange t t TC, Ty pe T -200~400 C; -320~752 F r r TC, Ty pe -50~1600 C; -58~2900 F j J TC, Ty pe J -200~00 C; -320~2200 F WE WE TC, We3/25 0~2300 C; 32~4200 F b b TC, Ty pe B 350~1800 C; 660~3300 F s s TC, Ty pe S -50~1600 C; -58~2900 F k k TC, Ty pe K -200~00 C; -320~2400 F e e TC, Ty pe E -200~900 C; -320~1650 F P10.0 P10.0 TD, Pt ~600.0 C; -99.9~999.9 F P100 P100 TD, Pt ~600 C; -320~00 F Cu50 Cu50 TD, Cu ~150.0 C; -60~300 F 5. Parameter Setting For safety reasons, the controller parameters are divided into three groups with Note 2. The value of outy determines the control mode. When it is set to: different pass codes. You should only give the code to those who have the 0 - elay J1, as alarm output; SS output disabled; responsibility and knowledge of how to properly change it. Code 0089 contains 1 - elay J1 as alarm output; as PID controlled relay contact output; SS the parameters for system configuration that may need to change during the output disabled;. initial set up. Code 0036 contains the parameters for tuning performance. 2 - elay J1, as alarm output; SS PID control output; Code 0001 is for controlling temperature and alarm settings. 3 - elay J1, as alarm output; SS On/off control output; P2/5 inty outy HY atdu psb rd corf end Output mode selection Hysteresis Band Input Sensor Selection Autotune offset Input offset Heating/Cooling Display Unit(C/F)

3 4 - elay J1 as alarm output; as On/off control relay contactor output; SS output disabled; 5 - elay J1 as alarm output; as Limit control relay contactor output; SS output disabled; 6 - elay J1, as alarm output; SS for Limit control output. Note 3. Hysteresis Band (also called dead band, or differential), Hy, is used for On/off control and Limit control. Its unit is in degrees ( C or F). For On/ off control mode, the output will be off when > and on again when <-Hy for heating. For cooling, the output will be off when < and on again when >+Hy. For Limit control mode, the controller can not be reset (to turn on the output) when >-Hy for heating, and when < +Hy for cooling. Note 4. The autotune offset will shift the value down by the Atdu value during the autotune process. That will prevent the system from damage due to overheating during the autotune. Note 5. Calibration offset, PSb is used to set an input offset to compensate the error produced by the sensor. For example, if the meter displays 5 ºC when probe is in ice/water mixture, setting PSb=-5, will make the controller display 0 ºC. To set negative value, shift to the very left digit, press down key until it shows PID Parameters (accessed by code 0036) The PID and relevant parameters are listed in table 3. To change the parameters, press, enter code 0036, and press again. The parameter flow chart is similar to Figure 3. Table 3. PID and relevant parameters Sy mbol Description Setting ange Initial Note P P Proportional Constant 0.1~99.9(%) I I Integral Time 2~1999(Sec) d d Deriv ativ e Time 0~399(Sec) 20 8 SouF SouF Damp Constant 0.1~ ot ot Cy cle ate 2~199(Sec) 2 10 FILt FILt Digital Filter Strength 0~3 0 End End Ex it The values of the P, I, and D parameters are critical for good response time, accuracy and stability of the system. Using the Auto-tune function to automatically determine these parameters is recommended for the first time user. If the auto-tuning result is not satisfactory, you can manually fine-tune the PID constants for improved performance. Note 6. Proportional Constant (P): P is also called the proportional band. Its unit is the percentage of the temperature range. e.g. For a K type thermocouple, the control range is 1500 C. P=5 means the proportional band is 75 C (1500x5%). Assuming the set temperature () = 200. When integral, I, and derivative, d, actions are removed - the controller output power will change from 100% to 0% when temperature increases from 5 to 200 C. The smaller the P value is, the stronger action will be for the same temperature difference between and. Note 7. Integral time (I): Brings the system up to the set value by adding to the output that is proportional to how far the process value () is from the set value () and how long it has been there. When I decreases, the response speed is faster but the system is less stable. When I increases, the respond speed is slower, but the system is more stable. Note 8. Derivative time (d): esponds to the rate of change, so that the controller can compensate in advance before - gets too big. A larger number increases its action. Setting d-value too small or too large would decrease system stability, cause oscillation or even non-convergence. Note 9. Damp constant: This constant can help the PID controller further improve the control quality. It uses the artificial intelligence to dampen the temperature overshot. When its value is too low, the system may overshoot. When its value is too high, the system will be over damped. SouF too low SouF acceptable SouF too high Figure 4. Damp constant Note 10. Cycle rate (ot): It is the time period (in seconds) that controller uses to calculate its output. e.g. If ot=2, and controller output is set to 10%, the heater will be on 0.2 second and off 1.8 seconds for every 2 seconds. Smaller ot result in more precision control. For SS output, ot is normally set at 2. For relay or contactor output, it should be set longer to prevent contacts from wearing out too soon. It normally set to 20~40 seconds. Note. Digital Filter (Filt): Filt=0, filter disabled; Filt=1, weak filtering effect; Filt=3, strongest filtering effect. Stronger filtering increases the stability of the readout display, but causes more delay in the response to changes in temperature. 5.3 Temperature setting and Alarm setting (accessed by code 0001) The temperature and alarm parameters are listed in table 4. To change the parameters, press, enter code 0001 an d press again. The parameter flow chart is similar to Figure 3. Table 4. Temperature and alarm parameters Sy mbol Description Initial Setting Note Target temperature(set Value) 800 AH1 AH1 J1 on temperature 800 AL1 AL1 J1 off temperature 900 AH2 AH2 on temperature 800 AL2 AL2 off temperature 900 END END Ex it Note. There are two ways to set the target temperature. a. During the normal operation mode, press or once to switch the display from to set value. The display will start to blink. Press or again to increase or decrease the. When finished, wait 8 seconds and the settings will take effect automatically (the display will stop blinking). b. Press key once. Use >, and keys to enter code Press key to confirm, then the display would be (Su). Press key again to display the setting. Use >, and keys to enter the new value and press to confirm. Press key to change the display to END. Then, press to exit. You can also ignore the steps after confirmation of. The controller will returns to normal operation mode automatically if no key is pressed for 1 minute. This method is easier for large temperature change. Note. Alarm setting. The J1 relay is controlled by parameters AH1 and AL1. And the relay is controlled by parameter AH2 and AL2. AH1 (or AL2) is the temperature to turn the J1 (or ) relay on; AL1 (or AL2) is the temperature to turn the J1 (or ) relay off. When AH1>AL1 (or AH2>AL2), the J1 (or ) alarm is set for absolute high alarm as shown in Figure 5 below. When AH1 <AL1 (or AH2<AL2), the J1 (or ) alarm is set for absolute low alarm as shown in Figure 6 below. When AH1=AL1 (or AH2=AL2), the J1 (or ) alarm is deactivated. Please note that can t be used as alarm when Outy is set to 1, 4 or 5. AH1 AL1 elay on AL1 AH1 elay on Figure 5. Absolute high alarm Figure 6. Absolute low alarm 6. Auto-Tuning The Auto-tuning function (also called self tuning) can automatically optimize the PID parameters for the system. The auto-tuning function will use the On/ off mode to heat up the system until it passes the set point. Then let it cool down. It will repeat this about three times. Based on the response time of the P3/5

4 system, the built-in artificial intelligence program will calculate and set the PID parameters for the controller. If your system has a very slow response, the auto-tuning could take a long time. AT start AT calculation AT end 9. Limit control mode. The Limit control mode will shut the heater off when is reached. The heater will not be turned on again until the controller is reset manually (press the key for 5 seconds). When powered on, it will not start the heating until reset button is pressed. The controller can t be reset when the temperature is within Hysteresis Band (Hy). To use the Limit control mode, set outy to 5 or 6. Then, set the Hy to the range that you want reset to be blocked. To start the heating or cooling, press key for 5 second or until the output indicator is on. ON OFF ON OFF ON/OFF PID Figure 7. Auto-tuning Start -Hy outy=5, =100, Hy=3. The heating stops after it reached 100 degree. 6.1 To activate Auto-tuning, press and hold > key until the AT indicator starts to blink, which indicates auto-tuning is in progress. When AT stops blinking, the auto-tuning is finished. Now, newly calculated PID parameters are set to be used for the system. Please note that Auto-tuning is only for PID control mode (when outy is set at 1 or 2). 6.2 To stop the Auto-tuning, press and hold > key until AT indicator stops blinking. Then, the previous PID parameters values are resumed. 7. On/off control mode On/off control mode is not as precise as PID control mode. However it is necessary for inductive loads such as motors, compressors, or solenoid valves that do not like to take pulsed power. It works like a mechanical thermostat. When the temperature passes the set point, the heater (or cooler) will be turned off. When the temperature drops back to below the hysteresis band (dead band) the heater will be turned on again. To use the on/off mode, set outy to 3 or 4 depending on the output device to be used. Then, set the Hy to the desired range based on control precision requirements. Smaller Hy values result in tighter temperature control, but also cause the on/off action to occur more frequently. In the PID parameters menu (code 0036), only ot and FILt are used. P, I, D and SouF are not meaningful elay On -Hy Figure 8. On/off control mode When heating, and outy=3 or 4, If (-Hy), relay on If, relay off (=100, Hy=3) 8. Manual mode Manual mode allows the user to control the output as a percentage of the total heater power. It is like a stove dial. The output is independent of the temperature sensor reading. One application example is controlling the strength of boiling during beer brewing. You can use the manual mode to control the boiling so that it will not boil over to make a mess. The manual mode can be switched from PID mode but not from On/off mode. To switch from the PID to the manual mode, press and hold the key until the AT/M indicator turned on (about 5 seconds). In the manual mode, the top display is for the process temperature. The bottom right is the percentage of power output. The bottom left display show an M for user to easily identify the controller is in manual mode. To switch from manual to PID mode, press and hold key until the AT/M indicator turned off. This controller offers bumpless switch from the PID to manual mode. If the controller outputs 75% of power at PID mode, the controller will stay at 75% when it is switched to the manual mode, until it is adjusted manually. elay on Figure 9. Limit control mode 10. Application Example 10.1 A water tank needs to be controlled at F. Alarm 1 will go off if T > F, Alarm 2 will go off, if T> F. The power source is 240V AC. The heating element is switched by a SS. A Pt100 TD sensor with 0.1 resolution input is used as the temperature sensor. 240VAC L1 L2 Heater 2 1 SS 3 4 Alarm1 240V buzzer Figure 10. Typical wiring set up for beer brewing and bird incubator. For smoker control, the TD sensor should be replaced by K type thermocouple b. Parameter setting. These are the parameters that need to be changed from the initial value: Inty=P10.0, =150.0 F, AH1=155.0 F, AL1=154.0 F, AH2=170.0 F, AL2=169.0 F. Auto-tune is used to set the PID parameters. Power up the controller. Press and hold the > key until AT starts to blink. The controller starts the Autotuning. When the AT stops blinking, the new PID parameters are generated for the system. The controller is in normal operation mode. The tank will be maintained at F. Please note that you don t not have to wire or set the alarm to control the temperature A furnace needs to be controlled at 00 F. The power source is 0V AC. The heating element is 1800W/0V. It is switched on/off by a contactor. The coil voltage of the contactor is 0V AC. A K type thermocouple is used as the temperature sensor. W TD J1 Alarm2 240V buzzer P4/5

5 K type TC b. Parameter setting. These are the parameters that need to be changed from the initial value: outy=1 for PID mode with relay output; ot=20 to increase the relay life time; =00 F for the target temperature A 24VAC solenoid valve is switched by relay in on/off mode. The valve will be on until temperature reaches 200 F. Then, it will shut off. When the temperature drops to below 195 F, it will be on again. Power source is 0V AC. A K type thermocouple is used as the temperature sensor. K type TC L N Figure. Typical wiring set up for powder coating oven and kiln. This diagram also applies to 240V AC power system, if both the heater and the coil voltage of the contactor are 240V AC. Figure. Typical wiring set up for a 24V gas, hot water valve, or a contractor with 24V coil voltage S Heater Contactor L N 24VAC Solenoid valve 0VAC 0VAC b. Parameter setting. These are the parameters that need to be changed from the initial value: outy=4 for on/off mode with relay output; Hy =5 degree, =200 F for the target temperature. Note, if this is to control a contactor with 24V coil, PID mode should be used. The setting should be same as example 2 except the value Control a small load without using any external SS or relay. K type TC Heater/cooler L 0VAC N Figure. Typical wiring set up for driving a 0V AC heater or cooler directly. Only low power device can be wired in this way. The current limit for resistive load is 3 Amp. The current limit for inductive load is lower, depending on the inductance. b. Parameter setting. These are the parameters that need to be changed from the initial value: outy= 1, 4 or 5 for relay output depending the control mode. ot=20 to increase the relay life time. d=1 if the load is a cooling device.. Error Message and trouble shooting.1 Display EEEE This is an input error message. The possible reasons are, the sensor is not connected correctly; the input setting is wrong type; or the sensor is defective. If this happens when using thermocouple sensor, you can short terminal 9 and 10. If the display shows ambient temperature, the thermocouple is defective. If this happens when using the TD sensor, check the input setting first because most controllers are shipped with input set for thermocouple. Then check the wiring. The two red wires should be on terminal 9 and 10. The clear wire should be on terminal 8..2 No heating When controller output is set for relay output, the AL2 LED is synchronized with output relay. When controller output is set for SS output, the OUT LED is synchronized with SS control output. If there is no heat when it is supposed to, check the AL2 or OUT first. If it is not lit, the controller parameter setting is wrong. If i t is on, check external switching device (if the relay is pulled-in, or the red LED of the SS). If the external switching device is on, then the problem is either the external switching device output, its wiring, or the heater. If the external switching device is not on, then the problem is either the controller output, or the external switch device..3 Poor Accuracy Please make sure calibration i s done by immersing the probe in liquid. Comparing with reference in air is not recommended because response time of sensor depends on its mass. Some of our sensor has response time >10 minutes in the air. When the error is larger than 5 F, the most common problem is improper connection between the thermocouple and the controller. The thermocouple needs to be connected directly to the controller unless thermocouple connector and extension wire is used. A copper connector, copper wire, or thermocouple extension wire with wrong polarity connected on the thermocouple will cause the reading drift more than 5 F. Auber Instruments Inc North Point Parkway, Suite 99, Alpharetta, GA info@auberins.com Tel: P5/5

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